Laminating body

ABSTRACT

A laminating body for laminating a foil onto a substrate includes a pressure area on which there is imprinted a structure which forms an embossing in the foil upon lamination of the foil onto the substrate.

BACKGROUND OF THE INVENTION

A. Field of the Invention

This invention relates to a laminating body for manufacturing laminateproducts by laminating a foil onto a substrate, and to a method formanufacturing such a laminating body and a method for manufacturing alaminate product by means of the laminating body.

B. Related Art

Relevant laminate products in the present case are primarily valuedocuments, identity and identification documents, chip cards or othercard-shaped data carriers and value carriers or the like. The substratecan consist here of an almost arbitrary suitable material, e.g. ofpaper, plastic or the like.

It is known to provide a pressure area of laminating bodies employedupon lamination with a structure in the form of depressions by milling,etching or engraving, said structure being embossed into thelaminated-on foil upon lamination and being perceptible in the resultinglaminate product. Such embossings can serve e.g. as security features ofthe relevant value documents or data carrier and, as such, representidentifying information, hard-to-forge embossed patterns or the like.

The manufacturing of structured laminating bodies according to thespecifications of a laminate product manufacturer by milling, etching orengraving requires elaborate production equipment and production steps,which must normally be carried out by a manufacturer of the laminatingbody within the framework of the production process. This not onlycauses high costs, but also results in relatively long production timesand delivery times, which leads to a lack of flexibility and lowreaction times for the laminate product manufacturer, in particular inthe case of laminate products to be manufactured urgently. This methodis likewise disadvantageous when only small batches of laminate productsare to be manufactured, because this requires a frequent change of thelaminating body solely due to changed embossed structures.

Therefore, it is the object of the present invention to optimize thestructuring of a laminating body so as to avoid the disadvantages of theprior art.

SUMMARY OF THE INVENTION

According to the invention, a pressure area of the laminating body hasan imprinted structure which is configured such that the structureincorporates into the foil upon lamination an embossing corresponding inmirror-image form to the structure. Accordingly, this structure, uponthe manufacture of the laminating body, is imprinted on the pressurearea thereof such that the structure, upon lamination of a foil onto asubstrate, is embossed into the foil in mirror-image form.

The imprinted structure is, in so doing, applied sufficiently raised orthick that it is embossed into the foil upon lamination. Moreover, thestructure is adequately hard and mechanically resistant. Also, thestructure is imprinted on the pressure area such that upon laminationthe structure does not adhere to the foil to be laminated on, but can bedetached therefrom without damage and without residue. Further, thestructure is sufficiently heat-resistant so as not to be damaged by aheating of the pressure area that might be required for lamination.

Imprinting the structure on the pressure area of the laminating body inaccordance with the invention requires substantially less technicaleffort than, for example, milling or etching. Accordingly, theimprinting is substantially simpler and faster to realize, more flexibleand more cost-efficient. The laminating body of the invention can alsobe printed with the structure outside elaborate production facilitiesand without high technical effort, e.g. by a laminate manufacturer, suchas e.g. a manufacturer of value documents and identity documents,card-shaped data carriers or the like.

This leads, on the one hand, to a considerable saving of time and costsand thus to an elevated flexibility, which is of great importance in thecase of individual requirements for laminate products to be produced,e.g. in the case of small batch sizes or urgent tenders for valuedocuments or card-shaped data carriers. Finally, by imprinting thestructures on site it can also be ensured that a laminating bodymanufacturer obtains no confidential information in connection with theembossed structures and their contents.

The laminating body may be in particular a laminating plate. Preferably,the laminating body consists of chromium steel which is preferablyhigh-gloss on one or both sides, or of brass which is preferablynickel-plated or chromium-plated and particularly preferably ishigh-gloss on one or both sides.

The imprinted structure can represent in particular individualizationdata or personalization data of users of the laminate products to bemanufactured, e.g. name and identity particulars in the case of nationalidentity cards or other identity cards.

Besides this, in principle arbitrary information and embossed patternsand embossed structures can be embossed with the imprinted structureinto the foils to be laminated on. Preferably, the structure forms inthe foil upon lamination one or several of the following embossings:

-   -   images, such as e.g. country contours, logos, guilloche patterns        or the like;    -   alphanumeric characters, e.g. in the form of especially small        microcharacters or as braille;    -   aids for technical processing of the laminate product, in        particular markings, insertion fields, height compensation        fields and strip fields;    -   areas with defined roughness, in particular for representing the        above-mentioned images and markings;    -   Multiple Laser Images (MLI), i.e. areas with several small        lenses which produce an optical effect dependent on the viewing        direction.

Height compensation fields refer in this connection to those regions ofthe imprinted structure that can compensate fluctuations in thickness ofthe laminate product, e.g. due to an object inserted therein, e.g. anelectronic component, in particular a display, a fabric band or thelike. On the other hand, height compensation fields can also producefluctuations in thickness of the laminate product which in turncompensate corresponding fluctuations in thickness of a further productinto which the laminate product is incorporated (e.g. a passport, inparticular a passport with a fabric band).

Imprinted areal structures with defined roughness can be in particularareas that are matt or smooth over the full area or partly. Preferably,there are provided in the imprinted structure matt areas with “negative”images in which the actual image is represented as smooth areas withinthe matt area.

The imprinted structure is preferably configured such that it forms atactilely perceptible embossing in the foil upon lamination.

The structure is preferably imprinted on the pressure area by means ofscreen printing and/or offset printing and/or UV offset printing. Offsetprinting and UV offset printing are particularly suited for producingextremely fine microstructures, such as e.g. microcharacters, and heightcompensation fields. Particularly preferably, a standard screen printingprocess is employed.

For printing the structure on the pressure area there is particularlypreferably employed a thermally stable lacquer, in particular a stovinglacquer, a UV lacquer or a tactile UV lacquer. Through the employment ofa thermally stable lacquer, a long life of the imprinted structure isguaranteed when the foil is heated for lamination.

In a preferred embodiment, the structure is imprinted on the pressurearea with a removable lacquer. In particular, the removable lacquer maybe a lacquer that can be removed again with a special cleaner. Afterremoval of the imprinted structure, another structure can be imprintedon the pressure area, i.e. the laminating body can be reused. This isparticularly expedient when there is imprinted a structure withindividual information which is to be embossed upon lamination only afew times.

In addition to the imprinted structures on the pressure areas of thelaminating body, there can be provided further structures which areetched, milled or engraved. This can be expedient for example whenmilled, etched or engraved structures produce a largely standardizedbasic embossing and the printed structures make individual additions tothis basic embossing, e.g. in the form of user- or batch-specificparticulars, such as e.g. names, denominations or the like.

DESCRIPTION OF THE DRAWINGS

Further features and advantages of the invention will result from thefollowing description of embodiment examples of the invention as well asfurther alternative embodiments in connection with the drawings, whichshow:

FIG. 1 schematically the steps of a method for imprinting a structure ona laminating body;

FIGS. 2a-2d schematically different laminating bodies with differentimprinted structures as a sectional drawing;

FIG. 3 schematically the pressure area of a laminating body withdifferent imprinted structures in plan view; and

FIGS. 4a, 4b schematically two different laminating apparatuses.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

FIG. 1 shows schematically the steps of a method for imprinting astructure on a laminating body 1 and subsequent employment of thelaminating body 1 for lamination.

After the beginning SB of the method, a laminating body 1 is first madeavailable in step S1 and optionally so prepared that it can subsequentlybe printed in step S2. The laminating body 1 can consist in principle ofany sufficiently heat-resistant and stable material. In the present casethere is employed a laminating body 1 of metal, preferably of chromiumsteel or brass or nickel-plated brass or chromium-plated brass.Particularly preferably, the laminating body of metal is high-gloss onone or both sides.

For preparing the imprinting, the laminating body 1 is optionallycleaned or polished. Also, there can be applied to the pressure area 2of the laminating body 1 an adhesion promoter or another chemicalsubstance that facilitates or makes possible the printing of thelaminating body 1 in step S2. Subsequently, in step S2 the laminatingbody 1 is printed with a suitable printing substance such that thepressure area 2 of the laminating body 1 has an imprinted structure 3which is so configured that it forms an embossing in the foil 51 uponlamination (cf. step S3).

In order for the imprinted structure 3 to effect an embossing in thefoil 51 upon lamination, it is sufficiently raised relative to thepressure area 2. Moreover, the imprinted structure 3 is adequately hardor mechanically resistant and does not adhere to the laminated-on foil51 after lamination, i.e. an adhesive connection that the structure 3might enter into with the foil 51 upon lamination is significantlyweaker than the connection of the structure 3 to the pressure area 2. Ifthe foil 51 is heated by the laminating body 1 or in another way forlamination, the structure 3 is moreover adequately heat-resistant.

The structure 3 can be imprinted on the pressure area 2 in any suitablefashion. Preferably there is used therefor a screen printing, offsetprinting or UV offset printing process, e.g. a standard screen printingprocess. For printing the structure 3 there is employed a thermallystable lacquer, e.g. a stoving lacquer, a UV lacquer or a tactile UVlacquer. There can also be employed a lacquer that can be removed againe.g. only with a special cleaner.

Examples of possible designs of the imprinted structure 3 arerepresented in cross section in FIGS. 2a to 2d . The imprinted structure3 a can be imprinted on the pressure area 2 over the full area and varyonly in its height (FIG. 2a ). In so doing, there can be produced notonly protruding structures 3 a, but also depressions relative to furtherimprinted structures 3 a.

The pressure area 2 represented in FIG. 2b is provided only partly withwide 3 b and narrow 3 c protruding imprinted structures, while otherregions of the pressure area 2 are not provided with imprintedstructures 3 b, 3 c. The imprinted structures 3 b, 3 c here havedifferent heights.

The pressure area 2 represented in FIG. 2c is provided with an imprintedstructure 3 d with defined roughness, an imprinted structure 3 e whichupon lamination leaves an MLI (Multiple Laser Image) as an embossing,and a further structure 3 f varying in its height. In particular forproducing an MLI 3 e, but also for producing arbitrary other structures3 f varying in their height, a special relief lacquer can be employed.The structure 3 d with defined roughness leaves upon lamination anembossing appearing matt. This structure 3 d can have in particular anRz value of 2-10 μm, whereby the Rz value states the areal roughness bymeans of the distance between the deepest valley and the highest peak ofthe rough area.

The pressure area 2 represented in FIG. 2d is provided as in FIG. 2bwith wide protruding imprinted structures 3 b. In contrast to FIG. 2b ,however, the pressure area 2 represented here is additionally providedwith depressions 4 which have been formed in the laminating body 1 byetching, milling or engraving and thus lie below the level of thepressure area 2.

The imprinted structures, as are represented by way of example in FIGS.2a to 2d , typically have a height of 2 to 10 μm, but can also have anyother height that is technically expedient and desired by a manufacturerof laminate products.

In FIG. 3 there is represented a pressure area 2 of a laminating body 1which is provided with imprinted structures 3 which upon laminationleave embossings in the form of an image of the contour of a country 31,of an image of a guilloche pattern 36, of alphanumeric characters 32, ofalphanumeric characters as braille 35, of a height compensation field33, of an MLI 34 as well as of a marking 37 for technical processing ofthe laminate product. The alphanumeric characters 32, 35 here representindividualization and personalization data.

Further, there can also be provided images in the form of logos,alphanumeric characters in the form of microcharacters, aids fortechnical processing of the laminate product in the form of insertionfields and strip fields, or arbitrary other structures which can beproduced in a foil 51 by embossing.

The structures 3 can also be provided in the form of areas with definedroughness, as described above in connection with FIG. 2c , in particularfor representing the above-mentioned images 31, 36 and markings 37. Theareas with defined roughness can be in particular areas that are matt orsmooth over the full area or partially. In particular, there can also beprovided matt areas with “negative” images, in particular logos, i.e.the images are represented by smooth areas within the matt area.

The imprinted structures 3 can be configured partly or quite generallysuch that they produce a tactilely perceptible embossing uponlamination.

In the method step S3 of FIG. 1, a foil 51 is finally laminated onto anarbitrary substrate 52 to produce a laminate product 50. In so doing,the structures 3 imprinted on the laminating body are embossed into thefoil 51, whereupon the method sequence represented in FIG. 1 finallyends SE.

The laminate product 50 may be, inter alia, a value document, a paymentproduct, an identity and identification document, a chip card or anothercard-shaped data carrier and value carrier or the like. In particular,the laminate product 50 may also be a national identity card, alaminated page of a passport, a company ID card, a bank card, a creditcard, a payment card (cash card), an insurance card, a membership cardor the like.

In FIGS. 4a and 4b , possible laminating apparatuses are indicated. Inthe laminating apparatus of FIG. 4a , the foil 51 is pressed with thepressure areas 2 of two laminating bodies 1 configured as plates ontothe substrate 52. The laminating bodies 1 are provided on their pressureareas 2 with imprinted structures 3 which are embossed into the foil 51during this process. Alternatively, only one of the laminating bodies 1can of course also be provided on its pressure area 2 with an imprintedstructure 3.

In order for the foil 51 to enter into an adhesive connection with thesubstrate 52, said foil is heated during compressing. Alternatively,self-adhesive foils 51 could also be employed, or an adhesive oradhesion promoter be applied to the foils 51 or the substrate 52. Thesubstrate 52 can consist in particular of paper or plastic, and the foil51 in particular of plastic.

In the laminating apparatus represented in FIG. 4b , the laminatingbodies 1 are configured as rollers with a circumferential pressure area2. The foils 51 are thus rolled onto the substrate 52. In so doing, theyare heated, through which the foils 51 enter into an adhesive connectionwith the substrate 52, and the laminate product 50 is produced.Simultaneously, the structures 3 imprinted on the pressure areas 2 areembossed into the foil 51. Alternatively, there can also be employed aself-adhesive foil 51 or an adhesion promoter. Likewise, only one of thelaminating bodies 1 can also be provided on its pressure area 2 with animprinted structure 3. The substrate 52 can consist in particular ofpaper or plastic, and the foil 51 in particular of plastic.

The imprinted structures 3 are shown in FIGS. 4a and 4b forrepresentational reasons as regular, periodically recurring structures3. In reality, the imprinted structures 3 are normally substantiallymore complex, as was described for example with reference to FIGS. 2 and3.

The invention claimed is:
 1. A laminating apparatus for manufacturing alaminate product, the laminating apparatus comprising: a pressingmechanism configured to apply a laminating force to laminate a foil to asubstrate, and a laminating body that presses the foil to the substrate,the laminating body including a pressure area configured to contact thefoil to press and laminate the foil against the substrate duringlamination, wherein the laminating body includes a contact surface ofthe pressure area, the contact surface of the pressure area beingconfigured to contact the foil as the foil is pressed against thesubstrate during lamination, the pressure area being configured totransmit a laminating pressure from the pressing mechanism to the foiland the substrate, only a portion of the contact surface includes animprinted structure, the imprinted structure including a mirror image ofan embossment, the imprinted structure including a thermally stablelacquer provided on the contact surface, and the laminating apparatus isconfigured such that an embossing is formed in the foil by pressing theimprinted structure against a portion of the foil while the pressingmechanism laminates the foil to the substrate by pressing the pressurearea against the foil.
 2. The laminating apparatus according to claim 1,wherein the laminating body includes a first roller and the pressurearea is a first circumferential pressure area at a circumferentialsurface of the first roller.
 3. The laminating apparatus according toclaim 2, wherein the laminating body further includes a second roller,the second roller being configured to provide a counter force to thelaminating force applied by the pressing mechanism.
 4. The laminatingapparatus according to claim 3, wherein the second roller having asecond circumferential pressure area at a circumferential surface of thesecond roller, the second circumferential pressure area has a secondcontact surface, the second contact surface of the secondcircumferential pressure area being configured to contact a second foilprovided on an opposite side of the substrate from the first foil suchthat the laminating apparatus presses the first foil against a firstsurface of the substrate while pressing the second foil against a secondsurface of the substrate, the first surface of the substrate beingopposite from the second surface of the substrate, at least a portion ofthe second circumferential pressure area includes a second imprintedstructure, the second imprinted structure including a secondmirror-image of a second embossment, the second imprinted structurebeing formed of a thermally stable lacquer provided on the secondcircumferential contact surface, and the laminating apparatus isconfigured such that a second embossing is formed in the second foil bypressing the second imprinted structure against a portion of the secondfoil while the pressing mechanism laminates the first foil and thesecond foil to the substrate.
 5. The laminating apparatus according toclaim 1, wherein the laminating body includes a first plate and thepressure area is a surface pressure area of the first plate.
 6. Thelaminating apparatus according to claim 5, wherein the laminating bodyfurther includes a second plate, the second plate being configured toprovide a counter force to the laminating force applied by the pressingmechanism.
 7. The laminating apparatus according to claim 6, wherein thesecond plate having a second surface pressure area, the second surfacepressure area has a second contact surface, the second contact surfaceof the second surface pressure area being configured to contact a secondfoil provided on an opposite side of the substrate from the first foilsuch that the laminating apparatus presses the first foil against afirst surface of the substrate while pressing the second foil against asecond surface of the substrate, the first surface of the substratebeing opposite from the second surface of the substrate, at least aportion of the second surface pressure area includes a second imprintedstructure, the second imprinted structure including a secondmirror-image of a second embossment, the second imprinted structurebeing formed of a thermally stable lacquer provided on the secondsurface pressure area, and the laminating apparatus is configured suchthat a second embossing is formed in the second foil by pressing thesecond imprinted structure against a portion of the second foil whilethe pressing mechanism laminates the first foil and the second foil tothe substrate.
 8. The laminating apparatus according to claim 1, furthercomprising a heating unit configured to heat the foil for lamination tothe substrate.
 9. The laminating apparatus according to claim 1, whereinthe mirror image of the embossment includes a mirror image of a multiplelaser image, a country contour, a guilloche pattern, alphanumericcharacters, or a machine-readable marking of the laminate product formedupon lamination.
 10. The laminating apparatus according to claim 1,wherein the laminating body includes a high-gloss laminating plateformed of steel, chromium steel, brass, nickel-plating, or chromiumplating.
 11. The laminating apparatus according to claim 1, wherein thethermally stable lacquer is a stoving lacquer or a UV-cured lacquer. 12.The laminating apparatus according to claim 1, wherein the thermallystable lacquer is removable with a cleaner.
 13. The laminating apparatusaccording to claim 1, wherein the pressure area further comprisesadditional structure that includes depressions that extend within thelaminating body beyond a surface level of the pressure area.
 14. Thelaminating apparatus according to claim 1, wherein the laminating bodycomprises a laminating plate.
 15. The laminating apparatus according toclaim 1, wherein the mirror image of the embossment includes a mirrorimage representation of personalization data of a user of the laminateproduct.
 16. The laminating apparatus according to claim 1, wherein theimprinted structure is a screen printing printed on the pressure area ofthe imprinted structure or the imprinted structure is an offset printingprinted on the pressure area.
 17. The laminating apparatus according toclaim 1, wherein an adhesion promoter is applied to the laminating body,the adhesion promoter facilitating adhesion of the thermally stablelacquer to the to the portion of the contact surface of the pressurearea.
 18. The laminating apparatus according to claim 1, whereinlaminating apparatus is configured to manufacture a value document, apayment product, an identification document, a chip card or anothercard-shaped data carrier, a value carrier, a national identity card, alaminated page of a passport, a company ID card, a bank card, a creditcard, a payment card, an insurance card, or a membership card.
 19. Thelaminating apparatus according to claim 1, further comprising anadhesive applicator configured to apply an adhesive or an adhesionpromoter to the foil or to the substrate during lamination of the foilto the substrate.
 20. The laminating apparatus according to claim 1,further comprising a foil supplier and a substrate supplier, wherein thefoil supplier includes a plastic foil or the substrate supplier includesa plastic substrate or a paper substrate.